Shift column cable assembly

ABSTRACT

A connector for connecting a cable strand to a ball stud. The connector includes a body and a socket formed in the body. The socket includes a pair of lever arms and a pair of bosses. The lever arms include lock projections used to retain the ball stud in the socket.

This is a division of the U.S. Pat. application Ser. No. 08/510,542filed Aug. 2, 1995 now U.S. Pat. No. 5,655,415.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a cable assembly, and more particularly, to atwo-piece assembly having an adjustment feature to adjust the effectivelength of the cable.

2. Description of the Related Art

Cable assemblies typically include a conduit and a core member in theform of a stranded wire cable or cable strand extending within theconduit. In use, the cable strand is attached at one end to a remotemember; for example, a transmission control arm, and is connected at theopposite end to an actuation member such as a vehicle shift lever. Theconnection is such that movement of the actuation member is transmittedthrough the cable strand and results in corresponding actuation ormovement of the remote member. A cable assembly may be used in a motorvehicle to enable a vehicle operator to engage or disengage a vehicletransmission.

It is important that the relative position of the actuation member andthe remote member be maintained; i.e., if the shift lever is placed inneutral, it is imperative that the vehicle transmission also be placedin neutral. During installation of a cable assembly, proper positioningof the respective parts is obtained by adjusting the overall length ofthe cable. This may be accomplished in one of two ways. First, theoverall length of the cable strand itself may be adjusted, or second,the overall length of the conduit may be adjusted, which in effect,adjusts the length of the cable strand; i.e., increasing the length ofthe conduit shortens the cable strand.

Installation of a transmission shift cable during vehicle assembly is atedious and time-consuming procedure. Normally, the cable assembly isattached to the transmission on one end thereof The opposite end, whichis to be attached to the vehicle shift lever, is left hanging on thevehicle chassis adjacent the transmission. Assembly of most modernautomobiles takes place in a two-part process. The power train andchassis are assembled separate from the vehicle body and interior. Thetwo main subassemblies of the vehicle are finally assembled or marriedin a final vehicle assembly plant. Thus, the transmission cable isattached to the chassis but remains loose until final assemblyprocedures. During final assembly, the cable assembly must be threadedthrough the various vehicle components prior to being attached to thevehicle firewall and ultimately to the shift lever. Once connected, thecable must be adjusted to maintain and properly position the relativecomponents; i.e., the transmission control arm and the shift lever. Sucha procedure increases vehicle assembly time and thus reducescorresponding vehicle production.

A further difficulty exists in that any connection made to couple thetransmission control arm to the shift lever must be made with less thana four-pound connection force to maintain the respective parts in theirproper positions. Any increase in assembly force generates a risk thateither the shift lever is moved from its proper position, typicallyneutral during assembly, or the transmission is shifted from neutralinto one of the drive gears.

SUMMARY OF THE INVENTION

Accordingly, the present invention is a unique cable assembly formed oftwo portions which are joined to form a complete assembly. The twoportions may be joined with less than the mandated four-pound connectionforce. Each portion is independently mounted and secured to therespective vehicle chassis and vehicle body prior to final assembly. Thecable assembly, according to the present invention, enables an operatorduring final assembly to connect the two portions and release anautomatic adjustment feature which provides the necessary lengthadjustment and thus reduces assembly time and increases vehicleproduction.

In general the cable assembly includes a transmission sub assemblyportion and a shift lever sub assembly portion. A terminal rod fittingis connected to one end of each of the respective sub assembly portionsand is used to connect the respective portions to either the shift leveror transmission control arm. The remaining ends of the cable assemblyare joined by a connector assembly during final assembly. The connectorassembly includes a pair of joint end fittings each attached torespective ends of the cable strand. During assembly, the joint endfittings are connected via a coupling joint. The respective conduit endsare connected by a coupling end fitting connected to one end of theconduit and a slider end fitting, attached to the conduit of theopposite portion. The slider end fitting is slidably disposed within ahousing connector. The housing connector and coupling end fitting areconnected and held in place by a coupling clamp.

A further aspect of the invention includes a lock means cooperating withthe housing connector to prevent relative movement between the sliderend fitting and the housing connector. In the preferred form, the lockmeans engages the slider end fitting to maintain proper adjustment ofthe conduit. In addition, the lock means acts to hold the slider endfitting in a shipping position; i.e., a position prior to final vehicleassembly. Upon disengaging the lock means from the shipping position,the slider end fitting is released. Action of a spring causes the sliderend fitting to move longitudinally relative to the housing connector toautomatically adjust the conduit and corresponding cable strand. Oncethe cable strand is properly adjusted, the lock means engages the sliderend fitting and prevents relative movement to maintain the slider endfitting in the adjusted position.

A second aspect of the invention is a terminal rod fitting used toattach the cable strand to the control arm of the transmission and tothe shift lever. In general, the terminal rod fitting includes an innerflexible lever arm which deflects outward to accept a ball stud. Theflexible lever arm provides a low installation force while maintaining ahigh retention force to prevent the ball stud from being withdrawn fromthe terminal rod fitting.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle assembly utilizing a cableassembly according to the present invention.

FIG. 2 is an elevational view of a cable assembly according to thepresent invention with portions removed for clarity.

FIG. 3 is a top view of the connector assembly, including a housing andcoupling end fitting, of the cable assembly of FIG. 2 with portionsremoved for clarity.

FIG. 4 is a longitudinal sectional view taken along lines 44 of theconnector assembly, including the housing and coupling end fitting, ofthe cable assembly of FIG. 2.

FIG. 5 is a top view of a coupling end fitting of the cable assembly ofFIG. 2.

FIG. 5a is a sectional view taken along lines 5a--5a of FIG. 5.

FIG. 6 is a top view of a housing connector of the cable assembly ofFIG. 2.

FIG. 6a is an elevational view of the housing connector illustrated inFIG. 6.

FIG. 6b is a sectional view taken along lines 6b--6b of FIG. 6.

FIG. 7 is a top view of a slider end fitting of the cable assembly ofFIG. 2.

FIG. 7a is an enlarged view of the area shown in circle 7a of FIG. 7.

FIG. 7b is an end view of the slider end fitting taken from the leftside of FIG. 7.

FIG. 7c is a sectional view taken along lines 7c--7c of FIG. 7.

FIG. 8 is a bottom view of a coupling clamp of the cable assembly ofFIG. 2.

FIG. 8a is an elevational view of the coupling clamp illustrated in FIG.8.

FIG. 9 is a cross-sectional view taken along lines 9--9 of FIG. 3.

FIG. 10 is a cross-sectional view similar to FIG. 9 illustrating theoperation of the coupling clamp of FIG. 8.

FIG. 11 is an elevational view of a locking clip of the cable assemblyof FIG. 2.

FIG. 11a is a rear view of the locking clip of FIG. 11.

FIG. 11b is a sectional view taken along lines 11b--11b of FIG. 11.

FIG. 12 is an exploded fragmentary sectional view of the joint endfittings and coupling joint of the cable assembly of FIG. 2.

FIG. 12a is a fragmentary sectional view of the assembled joint endfitting and coupling joint of FIG. 12.

FIG. 12b is an enlarged view of a portion of the area shown in circle12b of FIG. 12.

FIG. 13 is a sectional view taken along lines 13--13 of FIG. 4illustrating the locking clip in a pre-assembly position.

FIG. 13a is a sectional view illustrating the locking clip in anadjustment position.

FIG. 13b is a sectional view taken along lines 13--13 of FIG. 4illustrating the locking clip in an engaged or locked position.

FIG. 14 is a top view of a terminal rod fitting of the cable assembly ofFIG. 2.

FIG. 14a is a side view of the terminal rod fitting of FIG. 14.

FIG. 14b is a sectional view taken along lines 14b--14b of FIG. 14.

FIG. 14c is a sectional view taken along lines 14c--14c of FIG. 14.

FIG. 14d is a sectional view similarly to FIG. 14c.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring to the drawings, and more particularly to FIGS. 1 and 2thereof, a cable assembly, seen generally as 20, is shown for use inconnecting a control arm of a vehicle transmission, mounted to a vehiclechassis 22, to a shift lever located in a vehicle body 24. Asillustrated, the cable assembly 20 is a two-piece assembly having atransmission portion 26 and a shift lever portion 29. The transmissionportion includes a conduit 27 and cable strand 28 disposed therein formovement relative the conduit 27. The shift lever portion 29 alsoincludes a conduit 30 and a cable strand 31 disposed therein formovement relative the conduit 30. A terminal rod fitting 33 mounted onone end of the cable strand 28 of the transmission portion 26 is used toconnect the transmission portion 26 to the control arm of the vehicletransmission (not shown). A second terminal rod fitting 33 is connectedto one end of the cable strand 31 of the shift lever portion 29 and isused to connect the shift lever portion 29 to the shift lever arm (notshown) in the vehicle body 24. The transmission portion 26 is mounted tothe vehicle transmission via a connector 25 having a bayonet or twistand lock-style connection which attaches the transmission portion 26 tothe transmission. Additionally, the shift lever portion 29 is attachedvia the same or similar type of bayonet or twist and lock-type connector25 to the vehicle firewall which holds the shift lever portion 29 of thecable assembly 20 in position.

By making the control cable assembly 20 as a two-piece assembly, therespective portions may be shipped independently to various vehicleassembly or build areas, wherein as set forth above, each portion 26, 29of the cable assembly 20 may be separately installed. During finalassembly, the operator need simply connect the two free ends 42, 44 ofthe transmission portion 26 and shift lever portion 29 with theconnector assembly 46 cable and actuate the connector assembly 46enabling an automatic adjustment feature to remove any slack and provideappropriate tension in the cable strand. This can be accomplished in agreatly reduced time from that previously required to assemble andconnect a cable to the shift lever.

Turning now to FIGS. 3 and 4, a connector assembly, generally seen at46, is shown for use in connecting the respective free ends 42, 44 ofthe transmission portion 26 and the shift lever portion 29 of the cableassembly 20. The transmission portion 26 includes a coupling end fitting48 connected to the free end 42 of the conduit 27 (see FIG. 5a). Aslider end fitting 52 is connected to the free end 44 of the shift leverportion 29. Both connections are normally molded; i.e., the fittings aremolded directly over the conduit to provide a secure and sealedconnection. A housing connector 54, having a passageway 56 therein,slidably receives the slider end fitting 52 and allows relativelongitudinal movement to occur between the two respective parts. Alocking clip 58 disposed within a slot 60, transverse the passageway 56,is operative to prevent relative longitudinal movement between theslider end fitting 52 and the housing connector 54. The above elementsof the connector assembly 46 will be set forth in greater detail below.

The cable strands 28, 31 are connected by coupling joints 62. Asillustrated in FIG. 4 and more fully in FIGS. 12-12B, the end of eachcable strand 28, 31 includes a joint end fitting 64. The joint endfittings 64 are identical in nature and thus only one will be described.The joint end fitting 64 includes a body portion 66 which is attached tothe cable strand through conventional means.; e.g., crimping. A headportion 68 extends outward from the body portion 66. A reduced diameterneck portion 70; i.e., the overall diameter or size of the neck portion70 is less than that of the head portion 68. While the joint end fittingis disclosed herein as having a cylindrical shape or a circularcross-section, it is possible to use other shapes or cross-sections suchas square, hexagon or other polygons. As illustrated in FIG. 12b, ashoulder 72 is formed between the neck 70 and the head portion 68, Theshoulder 72 is inclined at an angle θ toward the neck portion. In thepreferred embodiment, the angle of inclination is approximately fourdegrees.

The joint end fittings are connected by a coupling joint 62. Thecoupling joint 62 is a cylindrical member having an inner diameter oropening slightly greater than the outer diameter or size of the head 68of the joint end fitting 64. The coupling joint 62 includes a pair ofinwardly extending resilient detent fingers 74. Once again, the couplingjoint 62 may take any shape as long as it is complementary to that ofthe joint end fitting 64.

In the preferred form, insertion of the joint end fitting 64 into thecoupling joint 62 causes the head portion 68 to engage the detent finger74 and deflect it outward. The resiliency of the detent finger 74 issuch that an axial installation force of four pounds or less will besufficient to deflect the fingers 74. Once the head portion passes theend of the detent finger 74, the finger snaps inwardly along the neckportion 70. When the cable strand 28 is pulled outward, i.e., tension isapplied to the strand, the end of the detent finger 74 engages theshoulder 72 and prevents withdrawal of the joint end fitting 64 from thecoupling joint 62. As shown in FIG. 12a, once the respective joint endfittings 64 are locked in position on the coupling joint 62, the cablestrands 28, 31 function effectively as a one-piece cable. Theinclination of the shoulder 72 causes the detent finger 74 to be pulledinward toward the neck 70 upon application of tension to the cablestrand 28, 31. Thus, as the tensile force is applied, the finger 74 isdrawn radially inwardly towards the neck portion 70 which increasescoupling force. Thus, the tensile force acts axially on the detentfinger 74 rather than radially. It should be appreciated that theremoval of the joint end fitting 64 from the coupling joint 62 isaccomplished by urging the joint end fitting 64 forward allowing thedetent finger 74 to be lifted upward until it clears the shoulder 72after which the joint end fitting 64 may be withdrawn.

As set forth above, this procedure interconnects the respective portionsof the cable strands 28, 31 for both the transmission portion 26 andshift lever portion 29 of the cable assembly 20. Now, the conduitsections 27, 30 must be connected. Connection of the conduit sections27, 30 is accomplished by utilizing the coupling end fitting 48, housingconnector 54, and slider end fitting 52 as set forth above. The couplingend fitting 48 is attached to the housing connector 54. As shown in FIG.5a, the coupling end fitting 48 includes a body 80 attached to theconduit 27. The body 80 includes an opening 82 of a size sufficient toreceive and allow longitudinal movement of the coupling joint 62 andjoint end fitting 64 combination within the body 80. As illustrated inFIG. 4, the cable strands 28, 31 and joint end fittings 64 movelongitudinally within the connector assembly 46. A receptacle end 84 onthe body 80 forms or includes a socket 86 which receive a plug portion88 extending outward from the housing connector 54 (see FIGS. 6-6d). Acoupling clamp 90 (see FIGS. 8-8a), cooperates with a transverse slot 92formed in the receptacle end 84 to couple the housing connector 54 tothe coupling end fitting 48.

In the preferred form, the coupling clamp 90 is installed in thetransverse slot 92 of the coupling end fitting 48 prior to installationof the plug portion 88 of the housing connector 54. The coupling clamp90 includes a load bearing surface 94 and an inclined installationsurface 96. The inclined installation surface 96 cooperates with abeveled installation surface 98 of the plug portion 88. As illustratedin FIGS. 9 and 10, when the plug portion 88 is inserted into the socket86, the inclined and beveled installation surfaces 96, 98 engage causingthe legs 100 of the coupling clamp 90 to be deflected outward and spreadapart. Once the beveled installation surface 98 on the plug portion 88clears the legs 100, the legs snap into a lock groove 102 on the housingconnector 54 such that the load bearing surface 94 of the coupling clamp90 engages a shoulder 103 of the lock groove 102 to secure the couplingend fitting 48 to the housing connector 54.

In order to protect the cable strand 28, 31 from the environment, ano-ring 106 positioned on an o-ring groove 108 located on the nose 110 ofthe plug portion 88 engages an interior seal surface 112 of the couplingend fitting 48. Such a seal prevents entry of contamination and otherforeign materials which could affect the longitudinal motion of thecable strands 28, 31.

Turning now to FIG. 7, the slider end fitting 52 for use with the cableassembly 20 is shown. The slider end fitting 52 includes a cylindricalbody 120 having a plurality of serrations 121 located along the outersurface thereof. While illustrated herein as cylindrical, the slider endfitting may have any particular cross-section desired, e.g., hexagonalor any other polygonal cross-sections. A passageway 124 is formed in thebody 120 and is of a sufficient size suitable to receive the joint endfittings 64 and coupling joint 62 in a manner enabling longitudinalmovement of the cable strands 28, 31 within the connector assembly 46and the slider end fitting 52. One end of the slider end fitting 52 isconnected to the conduit 30.

As set forth previously, the slider end fitting 52 is telescopicallydisposed within the passageway 56 of the housing connector 54. As theslider end fitting 52 moves relative to the housing chamber 54, theoverall length of the conduit, and thus the cable strand, may beadjusted. An o-ring 128 (see FIG. 4), is positioned in an o-ring groove126 and engages an inner surface 128 of the passageway 56 to preventintrusion of dirt and other foreign materials which could affect motionof the cable strands 28, 31.

As illustrated in FIG. 4, a spring 130 exerts an outwardly directedforce upon the slider end fitting 52 to urge the slider end fitting 52and attached conduit 30 outward thus eliminating or taking up any slackin the cable strands 28, 31. The spring 130 provides an automaticadjustment feature, which upon actuation, adjusts the length andcorresponding tension of the cable strands 28, 31.

During pre-assembly, i.e., when the shift lever portion 29 is assembledprior to attachment to the shift lever, the spring 130 is inserted intoa spring socket 132 of the slider end fitting 52. The spring 130 andslider end fitting 52 are inserted into the passageway 56 of the housingconnector 54 and the spring 130 is compressed until an assembly groove134 is aligned with a pair of lock tangs 136 extending from the lockingclip 58. As illustrated in FIG. 13, the lock tangs 136 prevent movementof the slider end fitting 52 during connection of the housing connector54 with the coupling end fitting 48 which connects the transmissionportion 26 of the cable assembly 20 to the shift lever portion 29 of thecable assembly 20.

While the plurality of serrations are shown in FIG. 7a as a plurality ofindividual tooth members 123 having inclined surfaces 125 on both sides,the tooth members may also be formed in different alignments,specifically, each tooth 123 may be formed to include a flat bearingsurface transverse the longitudinal axis of the slide end fitting 52 onone side and having a ratchet or guide surface inclined in one directionand generally transverse the longitudinal axis of the slide end fitting52 on the other side.

Turning now to FIGS. 11 through 11b, a locking clip 58 for use with thecable assembly 20 of the present invention is illustrated. The lockingclip 58 includes a plurality of serrations 140 on a surface thereof. Theserrations 140 of the locking clip may comprise a plurality ofindividual tooth members 141 complementary to the plurality ofserrations or individual tooth members 123 located on the outer surfaceof the slider end fitting 52. The complementary serrations, whenengaged, prevent movement of the slider end fitting 52 with respect tothe housing connector 54.

The locking clip 58 further includes several detent mechanisms to retainand couple the locking clip 58 to the housing connector 54. In theillustrated embodiment, a first set of deflectable, resilient fingers142 having outwardly projecting locking projections 144 on the endsthereof couple the locking clip 58 to the housing connector 54. Thelocking projections 144 coact with the housing to hold the locking clip58 on the housing. The locking clip 58 further includes a second set ofoutwardly deflectable resilient fingers 146 having inwardly projectinglocking projections 148 thereon. The inwardly locking projections 148cooperate with a plurality of retainer bars, seen generally at 150, FIG.6a, extending along the housing connections 54 adjacent the slot 60 inwhich the locking clip 58 is mounted. The inwardly projecting lockingprojections 148 cooperate with the retainer bars 150 to secure thelocking clip 58 in several positions along the housing connector 54.

Turning now to FIGS. 13-13b, the various positions of the locking clip58 in relation to the housing connector 54 and the slider end fitting 52are illustrated. FIG. 13a illustrates the locking clip positioned in ashipping or assembly position. As illustrated therein, the lock tangs136 are positioned in the assembly groove 134 and prevent longitudinalmovement of the slider end fitting 52 within the housing connector 54.As illustrated therein, the inwardly projecting lock projections 148engage the undersurface of a first retainer bar 152 to secure thelocking clip 58 in the assembly position. After connection of therespective joint end fittings 64 via the coupling joint 62 and theconnection of the housing connector 54 to the coupling end fitting 48,the locking clip is depressed for the first time by the operator,wherein the ramp surface 154 on the second retainer bar 156 causes thefingers 146 to be outwardly deflected and pass over the second retainerbar 156. Upon being urged past the second retainer bar 156, the fingers146 and corresponding inwardly projecting lock projections 148 snap intoengagement with the second retainer bar 156 with an audible click thusplacing the locking clip 58 in the adjustment position as shown in FIG.13a. As illustrated therein, the slider end fitting 52 is now free tomove longitudinally within the passageway 56 of the housing connector 54as the lock tangs 136 clear the lock grooves 134. In this position, thespring 130 acts to urge the slider end fitting 52 outwardly along thepassageway 56 to adjust the tension in the cable strand 28, 31. Once thecable strand 28, 31 is adjusted, the operator depresses the locking clip58 a second time, again urging and deflecting the arms 146 outwardlyover the ramp surface 160 of the third retainer bar 162 which causes theplurality of serrations 121 on the locking clip 58 to engage theplurality of serrations 140 on the slider end fitting 52 to preventrelative movement between the slider end fitting 52 and the housingconnector 54. Once again, the inwardly projecting locking projections148 snap into place on the third retainer bar 162 with an audible clickto inform the operator that the locking clip 58 is engaged with theslider end fitting 52.

The assembly provides a three-position locking clip 58 and retainer barcombination 150 which provides a shipping position, an adjustmentposition, and a final locking or engagement position. If furtheradjustment is deemed necessary, the outer deflectable fingers 146 may bewithdrawn from the engaged position and the locking clip 58 retracted toallow the spring 132 to further adjust the slider end fitting 52 andcorrespondingly take up or remove any slack from the cable strand 28,31.

Turning to FIGS. 14-14c, a further embodiment of the present inventionis illustrated. A terminal rod end fitting 33 for attaching the cableend to either the transmission control arm or shift lever is shown. Theterminal rod fitting 33 includes a body portion 200 connected to a rodmember 202 and a socket portion 220. The rod member 202 is connected tothe cable strand 28, 31 via conventional methods; e.g., crimping. It isimportant that the terminal rod fitting 33 be installed with aninstallation force of less than six pounds to prevent actuation ormovement of either the shift lever or the control arm than six pounds toprevent actuation or movement of either the shift lever or the controlarm connected to the transmission. However, the fitting 33 must maintainat least a twenty-pound retention force to keep the terminal rod fitting33 attached to a ball stud 216 having a shaft portion 218. This isaccomplished through use of a plurality of internal flexible lever arms204 which are attached to the body 200 via an integral hinge 206. Thehinge section 206 of the body allows the lever arm 204 to flex outwardto accept the ball stud 216 or other connector placed on the control armof the transmission. As illustrated in FIG. 14b, the terminal rodfitting 33 includes a pair of bosses 208 which prevent backwardsinsertion or installation of the fitting 33. In use, the fitting isinstalled such that the ball stud engages the ramp surfaces 210 on thelock projections 212 of the lever arms 204. The pressure of the ballstud 216 against the ramp surfaces 210 causes the lever arm 204 to beoutwardly deflected until the ball passes the lock projections 212 atwhich point the lever arms 204 spring inward adjacent the shaft portion218 to capture the ball stud 216 against the retaining surfaces 214.Upon an attempt to withdraw the ball stud 216 from the connector, theretaining surfaces 214, having pressure exerted upon them, tend to pullthe lever arms 204 inward thus preventing withdrawal of the ball stud216 from the fitting 33.

While only certain embodiments of the present invention have beendescribed, it will be apparent that the present invention, in light ofthe disclosure set forth above, may have various changes andmodifications made without departing from the spirit and scope of thepresent invention.

What is claimed is:
 1. A single piece connector for connecting a cablestrand to a ball stud, said single piece connector comprising:a body; asocket formed in said body, a pair of integral bosses located on an endof said body a pair of internal lever arms adjacent said socket, saidlever arms attached to said body by an integral flexible hinge, saidlever arms further including lock projections such that when said ballstud is inserted, said lever arms are deflected outward whereby the lockprojections clear a ball portion and engage a shaft portion of the ballstud, thus retaining the ball stud within the socket.
 2. A connector asset forth in claim 1 wherein said lock projections further include rampsurfaces, said ramp surfaces operative to engage said ball stud andassist in deflecting said lever arms outward.